US6883613B2 - Flow control apparatus for use in a wellbore - Google Patents

Abstract

An apparatus and method of controlling the flow of hydrocarbons into and/or out of a string of tubing disposed in a wellbore. In one embodiment, the apparatus comprises a tubular member having at least one aperture formed in a wall thereof and a sleeve disposed radially outward of the tubular member. The sleeve is selectively movable between a first position and a second position to control the flow between the outside and the inside of the tubular member. In one aspect, the apparatus further comprises a biasing member disposed adjacent the sleeve and adapted to apply a force against the sleeve in an axial direction and further comprises a piston adapted to receive a hydraulic pressure to move the sleeve against the force of the biasing member. In another aspect, the apparatus further comprises a electromechanical device adapted to selectively move the sleeve between the first position and the second position and further comprises a control line adapted to conduct an electrical current. In another embodiment, the apparatus comprises a tubular member having at least one aperture formed therein and a fixed ring and a rotatable ring disposed radially outward of the tubular member. In still another embodiment, the apparatus comprises a plurality of annular ribs having an inner surface, at least one support rod disposed along the inner surface of the annular ribs, and at least one control line disposed along the inner surface of the annular ribs.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No. 09/844,748, filed Apr. 25, 2001 U.S. Pat. No. 6,644,412. The aforementioned related patent application is herein incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention generally relates to an apparatus and a method of controlling the flow of hydrocarbons into and/or out of a string of tubing disposed in a wellbore. More particularly, the invention relates to an apparatus and a method of controlling the flow of hydrocarbons into a string of tubing that can be regulated remotely.

2. Description of the Related Art

FIG. 1 shows a cross-sectional view of atypical hydrocarbon well10. Thewell10 includes avertical wellbore12 and, thereafter, using some means of directional drilling like a diverter, ahorizontal wellbore14. Thehorizontal wellbore14 is used to more completely and effectively reached formations bearing oil or other hydrocarbons. InFIG. 1, thevertical wellbore12 has acasing16 disposed therein while thehorizontal wellbore14 has no casing disposed therein.

After thewellbore12 is formed and lined withcasing16, a string ofproduction tubing18 is run into thewell10 to provide a pathway for hydrocarbons to the surface of thewell10. The well10 oftentimes has multiple hydrocarbon bearing formations, such asoil bearing formations20,21,22 and/orgas bearing formations24. Typically,packers26 are used to isolate one formation from another. Theproduction tubing18 includes sections ofwellscreen28 comprising a perforated inner pipe (not shown) surrounded by a screen. The purpose of the wellscreen is to allow inflow of hydrocarbons into theproduction tubing18 while blocking the flow of unwanted material. To recover hydrocarbons from a formation where there iscasing16 disposed in the wellbore, such as atformations20 and21,perforations30 are formed in thecasing16 and in the formation to allow the hydrocarbons to enter thewellscreen28 through thecasing16.

In open hole wellbores, to prevent the collapse of the formation around thewellscreen28, a gravel packing operation is performed. Gravel packing involves filling theannular area32 between thewellscreen28 and thewellbore12,14 with sized particles having a large enough particle size such that the fluid will flow through the sized particles and into thewellscreen28. The sized particles also act as an additional filtering layer along with thewellscreen28.

FIG. 2 shows a cross-section view of a typical gravel packing operation in ahorizontal wellbore14. The sized particles are pumped at high pressures down thetubing18 as aslurry34 of sand, gravel, and liquid. Theslurry34 is directed into theannular area32 by across-over tool36. A second tubing (not shown) is run into the inner diameter of theproduction tubing18 in order to block the apertures of the perforated inner pipe of thewellscreen28. The second tubing prevents the liquid of theslurry34 from flowing into thewellscreen28. Thus, the slurry can be directed along the entire length of thewellscreen28. As theslurry34 fills theannular area32, the liquid portion is circulated back to the surface of the well throughtubing18, causing the sand/gravel to become tightly packed around thewellscreen28.

Referring back toFIG. 1, because the hydrocarbon bearing formations can be hundreds of feet across,horizontal wellbores14 are sometimes equipped with long sections ofwellscreen28. One problem with the use of these long sections ofwellscreen28 is that a higher fluid flow into thewellscreen28 may occur at aheel40 of thewellscreen28 than at atoe42 of thewellscreen28. Over time, this may result in a “coning” effect in which fluid in the formation tends to migrate toward theheel40 of thewellscreen28, decreasing the efficiency of production over the length of thewellscreen28. The “conning” effect is illustrated by aperforated line44 which shows that water from aformation bearing water46 may be pulled through thewellscreen28 and into thetubing18. The production of water can be detrimental to wellbore operations as it decreases the production of oil and must be separated and disposed of at the surface of thewell10.

In an attempt to address this problem, various potential solutions have been developed. One example is a device which incorporates a helical channel as a restrictor element in the inflow control mechanism of the device. The helical channel surrounds the inner bore of the device and restricts fluid to impose a more equal distribution of fluid along the entire horizontal wellbore. However, such an apparatus can only be adjusted at the well surface and thereafter, cannot be re-adjusted to account for dynamic changes in fluid pressure once the device is inserted into a wellbore. Therefore, an operator must make assumptions as to the well conditions and pressure differentials that will be encountered in the reservoir and preset the helical channel tolerances according to the assumptions. Erroneous data used to predict conditions and changes in the fluid dynamics during downhole use can render the device ineffective.

In another attempt to address this problem, one method injects gas from a separate wellbore to urge the oil in the formation in the direction of the production wellbore. However, the injection gas itself tends to enter parts of the production wellbore as the oil from the formation is depleted. In these instances, the gas is drawn to the heel of the horizontal wellbore by the same pressure differential acting upon the oil. Producing injection gas in a hydrocarbon well is undesirable and it would be advantageous to prevent the migration of injection gas into the wellbore.

In still another attempt to address this problem, a self-adjusting flow control apparatus has been utilized. The flow control apparatus self-adjusts based upon the pressure in the annular space in the wellbore. The flow control apparatus, however, cannot be selectively adjusted in a closed or open position remotely from the surface of the well.

Therefore there is a need for an apparatus and a method which controls the flow of fluid into a wellbore. There is a further need for an apparatus and method which controls the flow of fluid into a production tubing string which may be remotely regulated from the surface of the well while the apparatus is in use.

SUMMARY OF THE INVENTION

The present invention generally relates to an apparatus and a method of controlling the flow of hydrocarbons into and/or out of a string of tubing disposed in a wellbore. More particularly, the invention relates to a remotely regulatable apparatus and a method of controlling the flow of hydrocarbons into a string of tubing.

In one embodiment, the apparatus comprises a tubular member having at least one aperture formed in a wall thereof. The aperture provides fluid communication between an outside and an inside of the tubular member. A sleeve is disposed radially outward of the tubular member to selectively restrict the flow of fluid through the aperture. The sleeve is selectively movable between a first position and a second position to control a flow of fluid between the outside and the inside of the tubular member. The apparatus further comprises a movement imparting member for imparting movement to the sleeve.

In another embodiment, the apparatus comprises a tubular member having at least one aperture formed in a wall thereof. The aperture provides fluid communication between an outside and an inside of the tubular member. A sleeve is disposed radially outward of the tubular member. The sleeve is selectively movable between a first position and a second position to control the flow of fluid between the outside and the inside of the tubular member. The apparatus further comprises a electromechanical device adapted to impart movement to the sleeve and further comprises a control line adapted to supply an electrical current to the device from a remote location.

In still another embodiment, the apparatus comprises a tubular member having at least one aperture formed in a wall thereof. The aperture provides fluid communication between an outside and an inside of the tubular member. A fixed ring and a rotatable ring are disposed radially outward of the tubular member. The fixed ring and the rotatable ring have voids formed therethrough. The rotatable ring is selectively movable to align the voids of the fixed ring and the rotatable ring to create a passage through the fixed ring and the rotatable ring. The apparatus further comprises a chamber in communication with the passage and the aperture of the tubular member and serves to allow the flow of fluid to and from the aperture of the tubular member.

In one embodiment, a wellscreen is provided having a plurality of annular ribs with an inner surface, at least one support rod disposed extending longitudinally along the inner surface of the annular ribs, and at least one control line also running longitudinally along the inner surface of the annular ribs.

In another embodiment, the method comprises running at least two flow control apparatuses on a string of tubing into a wellbore. Each flow control apparatus comprises a tubular member having at least one aperture formed in a wall thereof. The aperture provides fluid communication between an outside and an inside of the tubular member. Each flow control apparatus is adapted to be set in a first position or in a second position permit differing amounts of fluid to flow therethrough. The method further comprises setting each of the flow control apparatuses in the first position or the second position after run in.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited features, advantages and objects of the present invention are attained and can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings.

It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.

FIG. 1 is a cross-sectional view of a typical hydrocarbon well including a tubing with filter members disposed thereon.

FIG. 2 shows a cross-section view of a typical gravel packing operation in a horizontal wellbore.

FIG. 3 is a cross-sectional view of a plurality of flow control apparatuses coupled to a string of tubing run into a wellbore.

FIGS. 4 and 5 are cross-sectional views of one embodiment of a flow control apparatus shown in two different positions.

FIG. 6 is a cross-sectional view of another embodiment of a flow control apparatus which is hydraulically actuatable.

FIG. 7 is a cross-sectional view of still another embodiment of a flow control apparatus which is hydraulically actuatable.

FIG. 8 is a cross-sectional view of one embodiment of a flow control apparatus which can be hydraulically actuated without the use of a hydraulic control line.

FIG. 9 is a cross-sectional view of another embodiment of a flow control apparatus which can be hydraulically actuated without the use of a hydraulic control line.

FIG. 10 is a cross-sectional view of one embodiment of a flow control apparatus which is actuated by electromechanical means.

FIG. 11 is a cross-sectional view of another embodiment of a flow control apparatus which is actuated by electromechanical means.

FIGS. 12-14 are side cross-sectional views of one embodiment of a rotatable ring and a fixed ring of the flow control apparatus of FIG.11.

FIG. 15 is a schematic view of another embodiment of a flow control apparatus which is actuated by a combination of a hydraulic pressure and an electrical current.

FIG. 16 is a cross-sectional view of one embodiment of a control line with a plurality of conduits.

FIG. 17 is a side-cross-sectional view one embodiment of a control line integrated with a screen.

FIG. 18 is a schematic view of one embodiment of a control line manifold.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 3 shows a cross-sectional view of one embodiment of a plurality of flow control apparatuses54-60 coupled to a string oftubing18 run in a wellbore. Included is at least onecontrol line50 which runs from thesurface52 to the flow control apparatuses54-60. Thecontrol line50 may be disposed on the outer surface of thetubing18 by clamps (not shown). The clamps may be adapted to cover and to protect thecontrol line50 on thetubing18 during run-in and operation in the well.

In one embodiment, each flow control apparatus comprises a tubular member (FIG. 4) having apertures formed in a wall thereof. The apertures provide fluid communication between an outside and an inside of the tubular member. Each flow control apparatus further comprises a screen disposed radially outward of the tubular member. Thecontrol line50 is adapted to individually or collectively set each flow control apparatus54-60 in a first position or a second position to control a flow of fluid between the outside and the inside of the tubular member. In the first position, a reduced amount of fluid is allowed to flow between the outside and the inside of the tubular member in comparison to the second position. For example, in the first position, the apertures are closed or partially closed to restrict flow of fluid therethrough into thetubing18. In a second position, the apertures are open or partially open to increase flow of fluid therethrough into thetubing18. Of course, the flow control apparatus may be adapted so that the flow control apparatus may be set in any position between the first position and the second position. In this manner, the flow of fluid into the wellbore at the location of the apertures is controlled.

Thecontrol line50 is adapted to supply a hydraulic pressure, to supply an electrical current, or to supplying both a hydraulic pressure and an electrical current to set the flow control apparatuses54-60, which is discussed in further detail below. Alternatively, the flow control apparatuses54-60 may be adapted to be adjusted by a hydraulic pressure provided by a second tubular member (not shown), such as a coiled tubing, adapted to be disposed in the inner diameters of the tubular members of the flow control apparatuses54-60. In addition, the flow control apparatuses54-60 may be adapted to be adjusted by a hydraulic pressure applied to the annular space between thetubing18 and the wellbore.

An operator at thesurface52 may set the flow control apparatuses individually or collectively in the first position, in the second position, or in position therebetween to control the flow of oil or other hydrocarbons through the flow control apparatuses54-60 into thetubing18. For example, an operator can set theflow control apparatus57 in a first position and set the flow control apparatuses58-60 in a second position to reduce the effect of “coning” near theheel40 of the horizontal sections of thetubing18. Additionally, the operator can choose to produce hydrocarbons from a certain formation by opening the apertures of the flow control apparatuses only at that formation. For example, the operator can set theflow control apparatuses54,57,58,59, and60 in the first position and set theflow control apparatuses55 and56 in the second position in order to produce oil fromformation21. Furthermore, in one embodiment, there is no limitation to the number of times the flow control apparatus can be set between the first position and the second position. Of course, the flow control apparatus can be adapted so that the flow control apparatus can only be set once. In addition, the flow control apparatuses may be used to control the flow of fluids out of thetubing18. For example, certain flow control apparatuses can be set in a second position in order to inject pressures into a particular formation.

In one embodiment, thecontrol line50 is coupled to acontrol panel62 at thesurface52 which adjusts the flow control apparatuses54-60 by operating thecontrol line50 through an automated process. Thecontrol panel62 may be self-controlled, may be controlled by an operator at thesurface52, or may be controlled by an-operator which sends commands to thecontrol panel62 through wireless or hard-line communications from aremote location64, such as at an adjacent oil rig. Furthermore, thecontrol panel62 may be adapted to monitor conditions in the wellbore and may be adapted to send the readings of the conditions in the wellbore to the remote location, such as to an operator to help the operator to determine how to set the flow control devices54-60.

FIGS. 4-11 are cross-sectional views of various embodiments of the apparatus of the present invention. For ease and clarity of illustration and description, the apparatus will be further described as if disposed in a horizontal position in horizontal wellbore. It is to be understood, however, that the apparatus may be disposed in a wellbore in any orientation, such as in a vertical orientation or in a horizontal orientation. Furthermore, the apparatus may be disposed in any tubular structure, such as in a cased wellbore or an uncased wellbore.

FIGS. 4 and 5 show a cross-sectional view of one embodiment of a flow control apparatuses which is hydraulically actuated. The flow control apparatus includes atubular member72 havingapertures74 formed therein for flow of fluid therethrough between the outside of thetubular member72 and the inside or the inner diameter of thetubular member72. Theapertures74 may be any shape, such as in the shape of a slot or a round hole. Aslidable sleeve76 is disposed radially outward of thetubular member72 and is selectively movable to cover or to uncover theapertures74 of thetubular member72. Alternatively, theslidable sleeve76 may itself have apertures which align or misalign with theapertures74 of thetubular member72 to control flow of fluids therethrough. Ascreen78 may be disposed radially outward of thesleeve76 to block the flow of unwanted material into theapertures74 of thetubular member72.

Thesleeve76 covers or uncovers theapertures74 by being positioned between a first position and a second position. In the first position, as shown inFIG. 4, thesleeve76 covers at least a portion of theapertures74 of thetubular member72 to partially or fully restrict inflow of fluid into the apparatus. In the second position, as shown inFIG. 5, thesleeve76 exposes at least a portion of theapertures74 of thetubular member72 to partially or fully allow inflow of fluid into the apparatus. The flow control apparatus may be designed whereby thesleeve76 assumes any number of positions, covering and/or exposing various numbers ofapertures74 of the tubular member.

In the embodiment ofFIGS. 4 and 5, apin80 or protrusion is inwardly disposed on thesleeve76 and is adapted to travel along aslot82 or groove formed on the outer surface of thetubular member72. A spring or another biasingmember84 disposed adjacent thesleeve76 pushes or biases thesleeve76 to be in either the first position or the second position. When thesleeve76 is in the first position as shown inFIG. 4, thepin80 is positioned atlocation88 on theslot82. When thesleeve76 is in the second position as shown inFIG. 5, thepin80 is positioned atlocation90 on theslot82. It is to be understood that theslot82 may be shaped in any number of different patterns so long as it is operable with a pin to move the sleeve axially and/or rotationally. It is to be further understood that the pin, sleeve, and piston may be separate, integrated, and/or unitary pieces.

A hydraulic pressure is utilized to move thesleeve76 between the first position and the second position. Thecontrol line50 is adapted to supply a hydraulic pressure to apiston chamber94 housing apiston86 coupled to thesleeve76. When the hydraulic pressure supplied to thepiston chamber94 against the surface ofpiston86 is greater than the force of the biasingmember84, thepiston86 moves and consequently thesleeve78 moves.

To move the sleeve from the first position to the second position, a hydraulic pressure is supplied by thecontrol line50 to thepiston chamber94 to move the pin fromlocation88 on theslot82 tolocation89. Thereafter, the hydraulic pressure can be released. Becauselocation89 is “below”tip96 of theslot82, the protrusion moves tolocation90 under the force of the biasingmember84 and, thus, thesleeve76 moves to the second position.

To move thesleeve76 from the second position to the first position, a hydraulic pressure is supplied by thecontrol line50 to thepiston chamber94 to move thepin80 fromlocation90 on the slot tolocation91. Thereafter, the hydraulic pressure can again be released. Becauselocation91 is “below”tip98, the protrusion moves tolocation88 under the force of the biasingmember84 and, thus, thesleeve76 moves to the first position.

Other embodiments of a flow control apparatus which are hydraulically actuated may be utilized without departing from the spirit of the invention. For example, the pin may be coupled to the outer surface of the tubular member while the slot is formed on the inner surface of the sleeve. There may be a plurality ofcontrol lines50 coupled to thepiston chamber94 in which one of the control line supplies a fluid while another control line returns the fluid.

FIG. 6 shows a cross-sectional view of another embodiment of a flow control apparatus which is hydraulically actuated. Specifically, the arrangement of thescreen78,control line50,slidable sleeve76, andapertures74 are different from the previous embodiments. Thecontrol line50 supplies a hydraulic pressure topiston86 to move thesleeve76 to cover or uncover theapertures74, such as between a first position and a second position. The apparatus may further include a slot (not shown) on the outer surface of thetubular member72 to position thesleeve76 in a first position or a second position to control the flow of fluid into the apparatus.

FIG. 7 shows a cross-sectional view of another embodiment of a flow control apparatus which is hydraulically actuated. In this embodiment, thetubular member72 hasapertures75 of varying size formed therethrough while the sleeve hasapertures77 formed therethrough. Thesleeve76 may be rotated by hydraulic pressure supplied by thecontrol line50 topiston86 to move thesleeve76 to cover or uncover theapertures75. Movement of the sleeve to a second position aligns anaperture77 of the sleeve with a certainsized aperture75 of thetubular member72. Alternatively, movement to a first position will cover theapertures75 of thetubular member72 thereby restricting the flow of fluid into the apparatus. Thesleeve76 is coupled to apin80 which is adapted to travel in aslot82 formed on the outer surface of the tubular member. The flow control apparatus is designed to permit rotation of the sleeve in a predetermined direction. Alternatively, the sleeve may have apertures of varying size which align or misalign with apertures of the tubular member.

Other embodiments of a flow control apparatus which are hydraulically actuated may be utilized without the use of a control line. For example,FIG. 8 shows a cross-sectional view of one embodiment of a flow control apparatus which is actuated by a secondtubular member182 having anorifice184 formed in a wall thereof. The secondtubular member182 is adapted to be disposed in the inner diameter of thetubular member72 and adapted to communicate a hydraulic pressure through theorifice184.Cups188 disposed on the inner surface of thetubular member72 direct the hydraulic pressure to aconduit186 located through thetubular member72. The hydraulic pressure flows through theconduit186 topiston chamber94 to provide a hydraulic pressure topiston86 to move thesleeve76 between a first position and a second position thereby controlling the flow of fluid into the apparatus. In one embodiment, the secondtubular member182 comprises coiled tubing.

In one embodiment, a method of actuating a plurality of flow control apparatuses with the secondtubular member182 as shown inFIG. 8 comprises running the secondtubular member182 to the flow control apparatus which is at a lowest point in a wellbore. The secondtubular member182 provides a hydraulic pressure to actuate that flow control apparatus. Thereafter, the secondtubular member182 is pulled up the wellbore to the next flow control apparatus to actuate that flow control apparatus and so on. In this manner, any number of flow control apparatus are remotely shifted using, for example, coiled tubing.

FIG. 9 shows a cross-sectional view of another embodiment of a flow control apparatus which is hydraulically actuated without the use of a control line. The flow control apparatus has anopening192 disposed through the outer wall of thepiston chamber94. Theopening192 allows fluid to flow from an annular space between the flow control apparatus and the wellbore into theopening192 and into thepiston chamber94. The flow control apparatus is adapted so that a hydraulic pressure flowed into the piston chamber againstpiston86 moves thesleeve76 to cover or uncover theapertures74, such as between a first position and a second position. The apparatus of this embodiment can be shifted simply by increasing the pressure of the wellbore adjacent theopening192.

FIG. 10 shows a cross-sectional view of one embodiment of one of an apparatus which is actuated by electromechanical means. The flow control apparatus includes atubular member102 havingapertures104 formed therein for flow of fluid therethrough. Theapertures104 may be any shape, such as in the shape of a slot or a round hole. Aslidable sleeve106 is disposed radially outward of thetubular member102 and has at least oneaperture107 formed therein. Thesleeve106 is adapted to be selectively rotated so that theaperture107 aligns, misaligns, or is positioned in any number of positions therebetween with theapertures104 of thetubular member102 to control flow of fluid therethrough. Ascreen108 may be disposed radially outward of thesleeve106 to block the flow of unwanted material into theapertures104 of thetubular member102.

Amotor110 is disposed proximate thesleeve106 and is coupled to agear112.Teeth114 are disposed on the outer surface of thesleeve106 and are associated with thegear112. Acontrol line50 provides electrical power to turn thegear112 which causes thesleeve106. In this manner, theaperture107 of thesleeve106 aligns, misaligns, or is positioned in any number of positions therebetween with theapertures104 of thetubular member106.

FIG. 11 shows a cross-sectional view of another embodiment of a flow control apparatus which is actuated by electromechanical means. The flow control apparatus includes atubular member122 havingapertures124 formed in a wall thereof. Theapertures124 may be any shape, such as in the shape of a slot or a round hole. Achamber housing133 is disposed radially outward of thetubular member122 to define achamber125 in communication with theapertures124. Arotatable ring126 is disposed radially outward of thetubular member122 adjacent to thechamber125. A fixedring127 is disposed radially outward of thetubular member122 adjacent to therotatable ring126. Both therotatable ring126 and the fixedring127 have voids or vias formed in an outer surface thereof. When the voids or vias overlap, apassage129 is formed to allow fluid to flow pass therotatable ring126 and the fixedring127 into thechamber125 and into theapertures124 of thetubular member122. Therotatable ring126 may be rotated so that the voids of therotatable ring126 and the fixedring127 overlap in any number of amounts so that the flow of fluid can be controlled into thechamber125. Ascreen128 may be disposed radially outward of thetubular member122 to block the flow of unwanted material into theapertures124 of thetubular member122.

FIGS. 12-14 show side cross-sectional views of one embodiment of therotatable ring126 and the fixedring127 of the flow control apparatus of FIG.11.Rotatable ring126 and fixedring127 are in the shape of a gear having teeth sections and void sections.FIG. 12 illustrates a position wherein the voids of the rotatable ring (not shown) and the fixedring127 overlap forming apassage129 to allow fluid to flow therethrough.FIG. 13 shows when the voids of therotatable ring126 and the fixedring127 partially over lap forming apassage129 which is reduced in size from the passage illustrated inFIG. 12 but still allowing fluid to flow therethrough.FIG. 14 illustrates a position of the rings when the voids of therotatable ring126 and the fixedring127 are not aligned. In this position, there is no passage formed to allow the fluid to flow therethrough.

Referring again toFIG. 11, amotor130 is disposed adjacent therotatable ring126 to rotate therotatable ring126. Acontrol line50 is disposed through thechamber housing133 and coupled to themotor130 to supply an electrical current to the motor. Alternatively, the position of therotatable ring126 and the fixedring127 could be manually set without the use of themotor130 and thecontrol line50.

FIG. 15 shows a schematic view of another embodiment of a flow control apparatus which is actuated by a combination of hydraulic pressure and electrical current. Acontrol line51 comprises a plurality of conduits in which one conduit is ahydraulic conduit142 supplying a hydraulic pressure and one conduit is anelectrical conduit144 supplying an electrical current. Thecontrol line51 runs along thetubing18 to the flow control apparatuses57-60 disposed at various locations in the wellbore. The hydraulic conduit is coupled to asolenoid valve141 located at each flow control apparatus57-60. In the preferred embodiment, the control line is supplied with a constant source of a hydraulic pressure. The electrical conduit is coupled to eachsolenoid valve141 to supply an electrical current to open and to close thevalve141. When thevalve141 is open, a hydraulic pressure is supplied to the flow control device such as those flow control devices described inFIGS. 4-7 to permit or restrict flow of fluid into the flow control devices. In another embodiment, asingle valve141 is associated for a plurality of flow control devices. In this case, opening the single valve causes a hydraulic pressure to be supplied to the plurality of flow control devices. Of course, a plurality ofcontrol lines50 may be used instead ofcontrol line51 with a plurality of conduits.

FIG. 16 shows a cross-sectional view of one embodiment of acontrol line51 with a plurality of conduits. Thecontrol line51 includes ahydraulic conduit142 which supplies a hydraulic pressure and includes anelectrical conduit144 which supplies an electrical current. Alternatively, a conduit may be adapted to be a fiber optic line or a communication line in order to communicate with gauges, devices, or other tools on the tubing string. Thecontrol line51 may further include acable146 to add tensile strength to thecontrol line51. The deliverline50 may also comprise apolymer148 encapsulating the conduits and the cable.

FIG. 17 shows a side cross-sectional view of one embodiment of an apparatus comprising the control line50 (or control line51) integrated with the screen. The arrangement provides a location for the control lines that saves space and protects the lines during run-in and operation. Thecontrol line50 may supply a hydraulic pressure, an electrical current, or a combination thereof. In one embodiment, the screen comprises a plurality ofannular ribs162. A plurality ofsupport rods164 run longitudinally along the inner surface of theribs162. One ormore control lines50 also run longitudinally along the inner surface of theribs162. In one embodiment, a perforatedtubular member166 is disposed radially inward of theribs162 and thesupport rods164. One method of constructing the screen is to shrink fit theribs162 over thesupport rods164,control lines50, and thetubular member72,102,122. In one embodiment, when the integrated control line/screen apparatus is used with a flow control apparatus having a slidable sleeve or a rotatable ring, such as the flow control apparatuses described inFIGS. 4-7,10 and11, thesupport rods164 are disposed axially away from the sliding sleeve or rotatable ring and do not interfere with the movement thereof. The integrated control line and screen may be used with any embodiment of the flow control apparatuses as shown inFIGS. 4-7,10,11, and15 which require a control line.

In one aspect, an apparatus with a control line integrated into a screen as shown inFIG. 17 allows the use of a control line when harsh wellbore operations exist around a screen. For example, as discussed above, a gravel packing operation is performed around a screen in which the slurry is injected in the annular area between the screen and the wellbore at high pressures. It the control line were disposed on the outer surface of the screen, the gravel/sand of the high pressure slurry would abrade and eat away at the control line. Disposing the control line on the inner surface of the screen protects the control line from the high pressure gravel/sand slurry. In another example, the apparatus with a control line integrated to a screen allows one to perform a fracture packing operation around a control line. Pressures used in a fracture packing are typically even greater than that when gravel packing.

One method of utilizing a flow control device of the present invention comprises gravel packing a wellscreen having at least one of the flow control apparatuses as discussed above. The flow control apparatuses are arranged whereby the apertures thereof are closed to the flow of fluid therethrough from the annular space between the flow control apparatuses and the wellbore. A gravel/sand slurry is injected into the annular space without the loss of liquid into the tubular member of the flow control apparatus. In one aspect, the method allows uniform packing of the wellscreen without the use of an inner pipe disposed inside the tubular member.

FIG. 18 shows a schematic view of one embodiment of a control line manifold. The control line manifold comprises oneelectrical inlet172 and onehydraulic inlet174 and comprises a plurality ofhydraulic outlets176. Anelectrical control line50a(or electrical conduit144) is coupled to theelectrical inlet172, and ahydraulic control line50b(or hydraulic conduit142) is coupled to thehydraulic inlet174. Hydraulic control lines50nare coupled to thehydraulic outlets176 to supply a hydraulic pressure to a plurality of flow control apparatuses. Theelectrical control line50aindexes or controls the control line manifold to communicate the hydraulic pressure fromhydraulic control line50bto certain hydraulic control lines50n. In one aspect, the control line manifold allows the control over a plurality of flow control apparatuses while at the same time minimizing the number of control lines which are run to the surface. For example, a single electrical control line and a single hydraulic control line can be run to the surface from a control line manifold to control a plurality of flow control apparatus. In one aspect, the flow control manifold minimizes the number of control lines which must be run to the surface through an inflatable packer or series of inflatable packers. Of course, other embodiment of the control line manifold may be devised having a different number and different kinds of inlets and outlets.

The embodiments of the flow control apparatus as shown inFIGS. 4-14 may be used alone, in combination with the same embodiment, or in combination with different embodiments. Any embodiment of the flow control apparatus as shown inFIGS. 4-14 may be used as the flow control apparatuses54-60 (FIG. 3) coupled to the string oftubing18.

While foregoing is directed to the preferred embodiment of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.

Claims (32)

1. A flow control apparatus for use in wellbore operations, comprising:

a tubular member having at least one aperture formed in a wall thereof, the aperture providing fluid communication between an outside and an inside of the tubular member;

a sleeve disposed radially outward of the tubular member, the sleeve being selectively movable between a first position and a second position to control the flow of fluid between the outside and the inside of the tubular member;

a electromechanical device adapted to impart movement to the sleeve; and

a control line adapted to supply an electrical current to the electromechanical device.

2. The flow control apparatus ofclaim 1, wherein the electromechanical device is a motor.

3. The flow control apparatus ofclaim 2, further comprising teeth formed on the outer surface of the sleeve and a gear coupled to the motor and associated with the teeth of the sleeve.

4. The flow control apparatus ofclaim 1, wherein in the first position a reduced amount of fluid may flow between the outside and the inside of the tubular member in comparison to the second position.

5. The flow control apparatus ofclaim 4, wherein in the first position the sleeve covers at least a portion of the at least one aperture of the tubular member.

6. The flow control apparatus ofclaim 1, wherein the electromechanical device is adapted to rotate the sleeve between the first position and the second position.

7. The flow control apparatus ofclaim 1, wherein the sleeve has at least one aperture formed in a wall therein and wherein in the second position the at least one aperture of the sleeve at least partially aligns with the at least one aperture of the tubular member.

8. The flow control apparatus ofclaim 7, wherein the sleeve has a plurality of different sized apertures.

9. The flow control apparatus ofclaim 7, wherein the tubular member has a plurality of different sized apertures.

10. The flow control apparatus ofclaim 1, further comprising a tubular screen disposed around the tubular member.

11. The flow control apparatus ofclaim 10, wherein the control line is integrated with the tubular screen.

12. A flow control apparatus for use in wellbore operations, comprising:

a tubular member having at least one aperture formed in a wall thereof, the aperture providing fluid communication between an outside and an inside of the tubular member;

a fixed ring and a rotatable ring disposed radially outward of the tubular member, the fixed ring and the rotatable ring having voids formed on an outer surface thereof, the rotatable ring being selectively movable to align the voids of the fixed ring and the rotatable ring to create a passage along the outer surface of the fixed ring and the rotatable ring; and

a chamber in communication with the passage and the aperture of the tubular member.

13. The flow control apparatus ofclaim 12, further comprising a tubular screen disposed around the tubular member.

14. The flow control apparatus ofclaim 13, further comprising a motor coupled to the rotatable ring and adapted to move the rotatable ring.

15. The flow control apparatus ofclaim 14, further comprising a control line adapted to supply an electrical current to the motor.

16. The flow control apparatus ofclaim 15, wherein the control line is integrated with the screen.

17. A system for controlling flow of hydrocarbons in wellbore operations, comprising:

a string of tubing; and

a plurality of flow control apparatuses coupled to the string of tubing,

each flow control apparatus comprising a tubular member having at least one aperture formed in a wall thereof, the aperture providing fluid communication between an outside and an inside of the tubular member, each flow control apparatus adapted to be set in a first position and in a second position to control a flow of fluid between the outside and the inside of the tubular member.

18. The system ofclaim 17, wherein in the first position a reduced amount of fluid may flow between the outside and the inside of the tubular member in comparison to the second position.

19. The system ofclaim 18, wherein in the first position the aperture is at least partially closed to restrict flow of fluid therethrough and in the second position the aperture is at least partially open to increase flow of fluid therethrough.

20. The system ofclaim 17, wherein one or more of the flow control apparatuses are adapted to be set between the first position and the second position by at least one control line.

21. The system ofclaim 20, wherein the at least one control line is adapted to provide an electrical current.

22. The system ofclaim 20, further comprising a control panel at the surface of the wellbore coupled to the at least one control line.

23. The system ofclaim 22, wherein the control panel is adapted to receive communications from a remote location.

24. The system ofclaim 22, wherein the control panel is adapted to send communications to a remote location.

25. A method of controlling flow in wellbore operations, comprising:

running in a plurality of flow control apparatuses coupled to a string of tubing, each flow control apparatus comprising a tubular member having at least one aperture formed in a wall thereof, the aperture providing fluid communication between an outside and an inside of the tubular member, each flow control apparatus adapted to be set in a first position and in a second position to control a flow of fluid between the outside and the inside of the tubular member; and

remotely setting each of the flow control apparatuses in the first position or the second position.

26. The method ofclaim 25, wherein in the first position a reduced amount of fluid may flow between the outside and the inside of the tubular member in comparison to the second position.

27. The method ofclaim 26, wherein in the first position the aperture is at least partially closed to restrict flow of fluid therethrough.

28. The method ofclaim 26, wherein the flow control apparatuses of a formation are set in the second position and wherein the flow control apparatuses of flow control apparatuses removed from the formation are set in the first position to isolation production of hydrocarbons from the formation.

29. The method ofclaim 26, wherein the flow control apparatuses located at a heal section of a horizontal tubing are set in the first position and wherein the flow control apparatuses in the toe section of the horizontal tubing are set in the second position.

30. The method ofclaim 26, wherein the flow control apparatuses are set in the first position, the method further comprising performing a gravel packing operation around the flow control apparatuses set in the first position.

31. The method ofclaim 25, wherein setting one of the flow control apparatuses from between the first position and the second position comprises supplying an electrical current to the one of the flow control apparatuses.

32. The method ofclaim 25, wherein setting comprises sending communications from a remote source to a control panel adapted to actuate the flow control apparatuses.

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